Ceramics with engineered microstructures via 3D printing and templated grain growth

Abstract

A three-dimensional (3D) printing composition includes ceramic filaments comprising an additive having an aspect ratio of at least 2:1. 3D printed ceramic articles include the ceramic filaments.

What is claimed is: 
     
       1. A three-dimensional (3D) printing composition, comprising:
 ceramic filaments, each ceramic filament comprising an additive and having an extrusion direction, at least 50% of the additive of each ceramic filament being aligned with respect to the extrusion direction, and each additive having an aspect ratio of at least 2:1. 
 
     
     
       2. The 3D printing composition of  claim 1 , wherein the additive is present in an amount of at least 2 weight % (wt. %). 
     
     
       3. The 3D printing composition of  claim 1 , further comprising a dispersant. 
     
     
       4. The 3D printing composition of  claim 1 , wherein the additive is a seed crystal. 
     
     
       5. The 3D printing composition of  claim 1 , wherein the additive is a dopant, a fiber, a whisker, a needle, a carbon nanotube, or any combination thereof. 
     
     
       6. The 3D printing composition of  claim 1 , wherein the 3D printing composition further comprises a binder. 
     
     
       7. A method of making a 3D ceramic article, the method comprising:
 forming ceramic filaments comprising an additive having an aspect ratio of at least 2:1, at least 50% of the additive being aligned with respect to an extrusion direction of the ceramic filaments; 
 3D printing the ceramic filaments in successive layers to form a 3D structure; and 
 densifying to form the 3D ceramic article. 
 
     
     
       8. The method of  claim 7 , wherein the additive is a seed crystal, a dopant, a fiber, a whisker, a needle, a carbon nanotube, or any combination thereof. 
     
     
       9. The method of  claim 7 , wherein the 3D ceramic article has a textured surface. 
     
     
       10. The method of  claim 7 , wherein forming the ceramic filaments comprises extruding a ceramic composition comprising the additive in an amount of at least 2 wt. %. 
     
     
       11. The method of  claim 7 , wherein forming ceramic filaments comprises mixing ceramic powder and a dispersant in a solvent and then drying to form a coated ceramic composition. 
     
     
       12. The method of  claim 11 , further comprising mixing the coated ceramic mixture with the additive and a binder. 
     
     
       13. The method of  claim 7 , wherein 3D printing is filament deposition modeling. 
     
     
       14. The method of  claim 7 , wherein densifying is removing a binder, sintering, hot isostatic pressing, or any combination thereof.